Absorbent pads and methods of making and using same

ABSTRACT

The present disclosure provides high-performance absorbent pads for use with food products, for example for inclusion with packaged meat. The present disclosure also provides food packages, packaged food products, and methods of packaging a food product using a high-performance absorbent pad as disclosed herein. The food product may be poultry or seafood or other food product that releases a liquid that the seller desires to control.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit under 35 U.S.C. 119(e) of U.S. Provisional Application No. 62/380,829, filed Aug. 29, 2016, and entitled “High-Performance Absorbent Pads and Methods of Making and Using Same”, which is hereby incorporated by reference herein in its entirety for all purposes.

TECHNICAL FIELD

The present disclosure relates to absorbent pads for use with food products, for example for inclusion with packaged meat.

BACKGROUND

Absorbent pads are frequently used in food packaging. Generally, absorbent pads used in packaged meat include a continuous or full-coverage absorbent region, yet often fail to efficiently absorb fluid shed from the packaged meat. Increasing the amount of absorbent material used in the pad may improve total fluid absorption, but also significantly increases production costs (e.g., material costs).

A need exists for improved absorbent pads for efficiently and inexpensively absorbing fluid released by packaged food, such as meat.

SUMMARY

In some embodiments, the present disclosure provides an absorbent pad comprising a first layer for contacting a food product, a second layer substantially opposite the first layer, and an absorbent material disposed between the first layer and the second layer. The absorbent material forms part of at least one absorbent region of the absorbent pad disposed adjacent to at least one non-absorbent region of the absorbent pad arranged for placement beneath at least a portion of the food product.

In some embodiments, the present disclosure provides an absorbent pad comprising a first multilayer film, wherein the first multilayer film comprises: a first layer, wherein the first layer comprises a non-permeable film for contacting a food product; a second layer substantially opposite the first layer, wherein the second layer comprises a permeable film; a third layer disposed between the first layer and the second layer, wherein the third layer comprises a cellulose tissue; and a fourth layer disposed between the first layer and the second layer, wherein the fourth layer comprises an absorbent material.

In some embodiments, the present disclosure provides a multilayer film comprising a first layer, wherein the first layer comprises a non-permeable film for contacting a food product; a second layer substantially opposite the first layer, wherein the second layer comprises a permeable film; a third layer disposed between the first layer and the second layer, wherein the third layer comprises a superabsorbent polymer; and a fourth layer disposed between the first layer and the second layer, wherein the fourth layer comprises an absorbent material.

In some embodiments, the present disclosure provides a food package comprising a tray and an absorbent pad comprising a first multilayer film, wherein the first multilayer film comprises: a first layer, wherein the first layer comprises a non-permeable film for contacting a food product; a second layer substantially opposite the first layer, wherein the second layer comprises a permeable film; a third layer disposed between the first layer and the second layer, wherein the third layer comprises a cellulose tissue; and a fourth layer disposed between the first layer and the second layer, wherein the fourth layer comprises an absorbent material.

In some embodiments, the present disclosure provides a packaged food product comprising a tray; a high-performance absorbent pad comprising a first multilayer film, wherein the first multilayer film comprises: a first layer, wherein the first layer comprises a non-permeable film for contacting a food product; a second layer substantially opposite the first layer, wherein the second layer comprises a permeable film; a third layer disposed between the first layer and the second layer, wherein the third layer comprises a cellulose tissue; and a fourth layer disposed between the first layer and the second layer, wherein the fourth layer comprises an absorbent material; a food product in contact with the first layer of the first multilayer film; and a cover in contact with the tray for retaining the food product within the tray.

In some embodiments, the present disclosure provides a method of packaging a food product, the method comprising inserting an absorbent pad into a tray; placing a food product onto the absorbent pad; and covering the food product and the tray with a cover, wherein the absorbent pad comprises a first multilayer film, wherein the first multilayer film comprises: a first layer, wherein the first layer comprises a non-permeable film for contacting a food product; a second layer substantially opposite the first layer, wherein the second layer comprises a permeable film; a third layer disposed between the first layer and the second layer, wherein the third layer comprises a cellulose tissue; and a fourth layer disposed between the first layer and the second layer, wherein the fourth layer comprises an absorbent material.

These and other embodiments are described more fully herein in view of the several Drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows a schematic, peeled view of layers in an absorbent multilayer film for use in high-performance absorbent pads consistent with various embodiments of the present disclosure.

FIG. 1B shows a cross-sectional schematic view of the absorbent multilayer film of FIG. 1A.

FIG. 1C shows a schematic, peeled view of layers in another absorbent multilayer film for use in high-performance absorbent pads consistent with various embodiments of the present disclosure.

FIG. 1D shows a cross-sectional schematic view of the absorbent multilayer film of FIG. 1C.

FIG. 1E shows a schematic, peeled view of layers in a non-absorbent multilayer film for use along with an absorbent multilayer film in high-performance absorbent pads consistent with various embodiments of the present disclosure.

FIG. 2 is a photograph of a high-performance absorbent pad consistent with various embodiments of the present disclosure.

FIG. 3 is a photograph of a high-performance absorbent pad consistent with various embodiments of the present disclosure.

FIG. 4 is a photograph of a high-performance absorbent pad consistent with various embodiments of the present disclosure.

FIG. 5 is a photograph of a high-performance absorbent pad consistent with various embodiments of the present disclosure.

FIG. 6A shows a cross-sectional schematic view of a high-performance absorbent pad consistent with various embodiments of the present disclosure.

FIG. 6B shows a cross-sectional schematic view of another high-performance absorbent pad consistent with various embodiments of the present disclosure.

FIG. 7 shows a schematic view of a packaged food product consistent with various embodiments of the present disclosure.

FIG. 8 shows a perspective and partial cutaway view of a packaged food product consistent with various embodiments of the present disclosure.

DETAILED DESCRIPTION

Referring generally to FIGS. 2-8, the present disclosure provides high-performance absorbent pads 200 comprising at least one absorbent region 100, and optionally at least one non-absorbent region 300. The absorbent region 100 may include an absorbent multilayer film 120 (see, e.g., FIGS. 1A-1D, 6A, and 6B), while the at least one non-absorbent region 300 may include a non-absorbent multilayer film 320 (see, e.g., FIGS. 1E, 6A, and 6B). In some embodiments, the high-performance absorbent pad 200 further comprises a non-absorbent border 350 substantially about the edge of the absorbent pad 200. In some embodiments, the non-absorbent border 350 may include the same material as the at least one non-absorbent region 300, such as non-absorbent multilayer film 320. In some embodiments, the high-performance absorbent pad 200 further includes at least one perforation line 400 (see, e.g., FIG. 5) for enabling sizing of the high-performance absorbent pad 200. The high-performance absorbent pads 200 are suitable for use in food packaging, for example for absorbing fluid shed by food products such as meat.

1. Multilayer Films for Absorbent Pads

Referring now generally to FIGS. 1A-1E, the present disclosure provides multilayer films suitable for use in absorbent pads. A high-performance absorbent pad 200 (see, e.g., FIGS. 2-8) consistent with the present disclosure may include an absorbent multilayer film 120 (see, e.g., FIGS. 1A-1D) and a non-absorbent multilayer film 320 (see, e.g., FIG. 1E).

a. Absorbent Multilayer Films

In various embodiments, the absorbent multilayer film 120 comprises a first layer 10 and a second layer 20 disposed substantially opposite the first layer 10. In some embodiments, the first layer 10 and the second layer 20 form outer layers of the absorbent multilayer film 120. In some embodiments, one or more layers are disposed between the first layer 10 and the second layer 20. In some embodiments, a third layer 30 is disposed between the first layer 10 and the second layer 20. In some embodiments, an absorbent layer 40 is disposed between the first layer 10 and the second layer 20. In some embodiments, the third layer 30 and the absorbent layer 40 are disposed between the first layer 10 and the second layer 20.

In some embodiments, the first layer 10 is impermeable to aqueous fluids, such as water, saline, or blood. In some embodiments, the first layer 10 comprises an impermeable film. In some embodiments, the first layer 10 is permeable to gases, such as oxygen or carbon monoxide. In some embodiments, the first layer 10 is impermeable to oxygen and/or carbon monoxide. In some embodiments, the first layer 10 comprises, consists essentially of, or consists of polyethylene. In other embodiments, the first layer 10 comprises, consists essentially of, or consists of polypropylene. In other embodiments, the first layer 10 comprises, consists essentially of, or consists of polyester.

In other embodiments, the first layer 10 comprises, consists essentially of, or consists of a permeable material, such as a non-woven material (e.g., WO334CD, WO334CR, WO334BC, WO360XB, WO360XR, WO376CD, or WO376XW, Berry Plastics Corp., Evansville, Ind.). In some embodiments, the permeable material of the first layer 10 comprises a nonwoven material. In some embodiments, the nonwoven material includes a hydrophilic surfactant coating to make the non-woven material permeable.

The surfactant coatings applied to the nonwoven material that impart hydrophilicity to the layers are typically a cationic, anionic, nonionic or amphoteric surfactant. Normally, the hydrophilic coating is a nonionic surfactant such as alkylphenol ethoxylates, alkylphenyl polyethylene glycol ethers (including alkylaryl polyether alcohol, polyethylene glycol mono-(4-octylphenyl) ether, polyethylene glycol mono-(4-tert-octylphenyl) ether, polyoxyethylated octylphenol, ethoxylated octylphenol, octylphenol ethyleneoxide_(x) where X stands for the average units of ethylene oxide). The surfactant will have a range of ethylene oxide units from 1 to 40 with a calculated Hydrophilic/Lipophilic Balance (“HLB”) of 2 to 20. HLB is an arbitrary scale from 0 to 40 depicting the hydrophilic/lipophilic balance of a surfactant. Examples of the hydrophilic coating include TRITON X-35™, X-45™, X-100™, X-102™, X-405™ from Dow Chemical Co., OTIX 3, 10, and 40™ from Sasol Chemical Industries of Bad Homberg, Germany, and Polystep OP-9™, OP-3070™, and OP-4070™ from Stepan Co. of Northfield, Ill.

Additional sources of nonionic surfactants include combinations of ethers of phenol, polyethylene glycol, alkylphenol, and polypropylene glycol, polysorbates, fatty amine oxides, linear alcohol ethoxylates, alkanolamides, and block copolymers of ethylene oxide and propylene oxide and dimethylsiloxane based that are coupled to polar groups such as poly(oxethylene) containing the hydrophilic moiety, and mixtures thereof. Although any hydrophilic composition could be used, preferred compositions include Cirracol® PP842 fiber finish, obtainable from Uniquema. All the components in Cirracol® PP842 can be used in applications where direct food contact is desired. However, the hydrophilic coatings are not limited to above recited surfactants and any surfactant may be substituted provided that it adheres to the upper and lower layers, is food-grade compatible, and imparts hydrophilicity thereto.

The hydrophilic coating may be advantageously applied to the first layer 10 in an amount of from about 0.05 to 10 percent based on the weight of the nonwoven first layer 10. Typically, the coating is applied in an amount from about 0.1 to 2.0 weight percent. Somewhat more typically, the coating is applied in an amount from about 0.5 to 1.0 percent. The hydrophilic coating applied to a layer 10 may be in an amount from about 0.0 to 1.0 percent based on the weight of the nonwoven layer 10. Typically, the coating is applied in an amount from about 0.01 to 0.75 percent. Somewhat more typically, the coating is applied in an amount from about 0.01 to 0.35 percent. It should be understood that the present invention is not limited to the proportions and percentages of hydrophilic coatings recited above and that other percentages or proportions of hydrophilic coatings may be used depending upon the desired rate of wicking that is sought. Additionally, changing the basis weight (permeability) of the nonwoven material can control the rate of wicking. Reference may be made U.S. Pat. No. 7,025,198 and US Pub. No. 2012/0003372 (both of which are incorporated herein by reference) for further information on use of surfactants to control permeability in nonwoven materials in absorbent pads.

In some embodiments, the second layer 20 is permeable or substantially permeable to aqueous fluids, such as water, saline, seawater, and blood. In some embodiments, the second layer 20 comprises, consists essentially of, or consists of a nonwoven film. As used herein, the term “nonwoven film” refers to a substantially flat, porous sheet made from fibers or molten plastic/plastic film (e.g., without converting the fibers or molten plastic/plastic film into thread or yarn). In some embodiments, the nonwoven film comprises, consists essentially of, or consists of one or more of: polypropylene, rayon, polyolefin, polyethylene, and/or polyester. In some embodiments, the second layer 20 comprises, consists essentially of, or consists of a non-permeable material including a plurality of one-way fluid valves, which may be in the form of perforations formed by a pin wheel or other suitable means. For example and without limitation, in one embodiment, the second layer 20 comprises, consists essentially of, or consists of polyethylene sheet equipped (e.g., punched) with a plurality of one-way fluid valves.

In some embodiments, the third layer 30 is a fluid-permeable layer and is generally disposed between the first layer 10 and the second layer 20. The third layer 30 generally improves methods of making the high-performance absorbent pads 200 by providing a carrier material to the absorbent layer 40. Accordingly, in some embodiments, the high-performance absorbent pad 200 does not include the third layer 30. In embodiments of the high-performance absorbent pad 200 that include a third layer 30, the third layer 30 comprises, consists essentially of, or consists of a relatively stiff material, such as a sheet of material. In some embodiments, the third layer 30 comprises, consists essentially of, or consists of cellulose (e.g., cellulose tissue, such as Cellulose Tissue Grades 3423 and 3087 (Dunn Paper, Gouverneur, N.Y.), or Cellulose Tissue Grades 3414, 3424 and 4205 (Little Rapids Corp., Shawano, Wis.)).

The absorbent layer 40 is disposed between the first layer 10 and the second layer 20, and absorbs aqueous fluid such as water, saline, seawater, and blood. In some embodiments, the absorbent layer 40 is disposed between the first layer 10 and the third layer 30. In some embodiments, the absorbent layer 40 comprises fibrous wood pulp 42 (see, e.g., FIGS. 1B-1D). In some embodiments, the absorbent layer 40 comprises an absorbent polymer 44 (see, e.g., FIGS. 1B-1C). In some embodiments, the absorbent polymer 44 comprises a polyacrylate, such as sodium polyacrylate. In some embodiments, the absorbent polymer 44 comprises a crosslinked polymer, such as crosslinked sodium polyacrylate. In some embodiments, the absorbent layer 40 comprises fibrous wood pulp 42 and an absorbent polymer 44 (see, e.g., FIGS. 1B-1C).

In some embodiments, the absorbent multilayer film 120 further comprises an adhesive layer 50 (see, e.g., FIGS. 1B and 1D) disposed adjacent to the first layer 10 and between the first layer 10 and the second layer 20. In some embodiments, the adhesive layer 50 enables the absorbent layer 40 to adhere (e.g., to temporarily adhere or to permanently adhere) to the first layer 10. In some embodiments, the adhesive is a hot melt adhesive such as TECHNOMELT D 612D DISPOMELT (Henkel, Corp., Rocky Hill Conn.).

Referring now specifically to FIGS. 1C-1D, in some embodiments, the absorbent multilayer film 120 comprises the first layer 10 and the second layer 20 disposed substantially opposite the first layer 10. The first layer 10 and the second layer 20 may be substantially the same as described above. In some embodiments, the absorbent layer 40 of the absorbent multilayer film 120 comprises a superabsorbent layer 41 and an absorbent fiber layer 42. In some embodiments, the absorbent layer 40 is able to absorb about 100 g/ft² to about 1500 g/ft² of fluid. In some embodiments, the superabsorbent layer 41 comprises a layer of a superabsorbent polymer 44 disposed between layers of backing material 35 (see, e.g., FIG. 1C). In some embodiments, the superabsorbent polymer 44 comprises, consists essentially of, or consists of a food-safe hydrophilic polymer such as an optionally crosslinked polyacrylate (e.g., sodium polyacrylate; Flavor®-Pac 590 or Flavor®-Pac 593 (Evonik Corp., Greensboro, N.C.)). In some embodiments, the backing material 35 comprises, consists essentially of, or consists of cellulose tissue. In some embodiments, the absorbent fiber layer 42 comprises, consists essentially of, or consists of cellulose fiber (e.g., Golden Isles® Fluff Pulp Grade 4881 (GP Cellulose, Atlanta, Ga.)). In some embodiments, the absorbent fiber layer 42 comprises, consists essentially of, or consists of at least one layer (e.g., 1 layer, 2 layers, 3 layers, 4 layers, 5 layers, 6 layers, 7 layers, 8 layers, 9 layers, 10 layers, or more than 10 layers) of absorbent paper. In some embodiments, the absorbent multilayer film 120 comprises an adhesive layer 50 disposed between the first layer 10 and the absorbent layer 40.

In some embodiments, the absorbent layer 40 comprises an antimicrobial agent. In some embodiments, the antimicrobial agent is present in an amount sufficient to inhibit growth of a bacterial culture within the high-performance absorbent pad 200. In other embodiments, the antimicrobial agent is present in an amount sufficient to reduce an amount of microbes in fluid absorbed by the high-performance absorbent pad 200. In some embodiments, the antimicrobial agent is present in an amount sufficient to increase the amount of fluid absorbed by the high-performance absorbent pad 200 (e.g., expressed as grams of absorbed fluid per gram of absorbent layer 40). In some embodiments, the antimicrobial agent is present in an amount sufficient to reduce the amount of microbes (e.g., reduce the number of microbial colonies) present on/in a food product packaged with a high-performance absorbent pad 200 as described herein. In some embodiments, the antimicrobial agent is present in an amount sufficient to reduce, substantially eliminate, or eliminate odors emanating from a packaged food product comprising a high-performance absorbent pad 200 as described herein. In some embodiments, the antimicrobial agent is dispersed within the fibrous wood pulp 42. In other embodiments, the antimicrobial agent is dispersed within the superabsorbent polymer 44.

b. Non-Absorbent Multilayer Films

Referring to FIG. 1E, non-absorbent multilayer films 320 consistent with the present disclosure typically comprise the first layer 10 and the second layer 20 substantially opposite the first layer 10. The first layer 10 and the second layer 20 may be substantially the same as described above with respect to the absorbent multilayer films 120. While these multilayer films are described as “non-absorbent,” one of skill in the art will understand that some small amount of fluid may be absorbed by such multilayer films, for example through capillary action, surface adsorption, hydration, and similar phenomena. Accordingly, non-absorbent multilayer films 320 of the present disclosure may absorb a small amount of fluid without departing from the scope of this disclosure. For example, in some embodiments, a non-absorbent multilayer film 320 is capable of absorbing relatively less fluid (e.g., aqueous fluid) than a comparable amount of an absorbent multilayer film 120 disclosed herein is capable of absorbing.

In some embodiments, the first layer 10 is impermeable to aqueous fluids, such as water, saline, or blood. In some embodiments, the first layer 10 comprises an impermeable film. In some embodiments, the first layer 10 is permeable to gases, such as oxygen or carbon monoxide. In other embodiments, the first layer 10 is impermeable to oxygen and/or carbon monoxide. In some embodiments, the first layer 10 comprises, consists essentially of, or consists of polyethylene. In other embodiments, the first layer 10 comprises, consists essentially of, or consists of polypropylene. In other embodiments, the first layer 10 comprises, consists essentially of, or consists of polyester.

Alternatively, in other embodiments, the first layer 10 comprises, consists essentially of, or consists of a permeable material, such as a non-woven material (e.g., WO334CD, WO334CR, WO334BC, WO360XB, WO360XR, WO376CD, or WO376XW, Berry Plastics Corp, Evansville, Ind.). In some embodiments, the permeable material of the first layer 10 and/or the second layer 20 comprises a nonwoven material. In some embodiments, the nonwoven material includes a surfactant, which may be useful to make some nonwoven materials permeable.

In some embodiments, the second layer 20 of the non-absorbent multilayer film 320 is permeable or substantially permeable to aqueous fluids, such as water, saline, seawater, and blood. In some embodiments, the second layer 20 comprises, consists essentially of, or consists of a nonwoven film. In some embodiments, the nonwoven film comprises, consists essentially of, or consists of one or more of: polypropylene, rayon, polyolefin, polyethylene, and/or polyester (e.g., PE Film catalog no. 100352505, 100321882, 100079623, 100077955, 100079568, 100537892, 100034558, 100034559, 100067727, 100537891, 100045751, 100077952, 100035044, 100035045, 100056814, 100035043, 100035040, 100035047, 100035038, 100034557, 100035046, 100364097, 100538528, 100168732, 100048205, 100237200, 100764159, 100574567, 100056813, 100894283, 100937656, 100047347, 100214490, 100705944, 100815328, 100318913, 100555337, 100045621, 100048201, 100214459, 100035035, 100294723, 100035056, 100399151, 100399120, 100279197, 100279198, 100794842, or 100057076 (Sealed Air Corp., Lenior, N.C.)). In some embodiments, the second layer 20 comprises, consists essentially of, or consists of a non-permeable material including a plurality of one-way fluid valves. For example and without limitation, in one embodiment, the second layer 20 comprises, consists essentially of, or consists of polyethylene sheet equipped (e.g., punched) with a plurality of one-way fluid valves.

In some embodiments, the non-absorbent multilayer film 320 further includes a third layer 30 disposed between the first layer 10 and the second layer 20. In some embodiments, the third layer 30 is a fluid-permeable layer. The third layer 30 may be substantially the same as described above with respect to the absorbent multilayer films 120. In some embodiments, the third layer 30 comprises, consists essentially of, or consists of cellulose (e.g., cellulose tissue). Alternatively, in some embodiments, the non-absorbent multilayer film 320 does not include the third layer 30. For example, the non-absorbent multilayer film 320 may not include the third layer 30 in embodiments in which the absorbent multilayer film 120 does not include the third layer 30.

In some embodiments, the non-absorbent multilayer film 320 comprises an adhesive layer 50 disposed adjacent to the first layer 10 and between the first layer 10 and the second layer 20, or between the first layer 10 and the third layer 30.

2. High-Performance Absorbent Pads

Referring now generally to FIGS. 2-6, the present disclosure provides high-performance absorbent pads 200. Typically, a high-performance absorbent pad 200 consistent with the present disclosure comprises at least one absorbent region 100 and at least one non-absorbent region 300. Optionally, a high-performance absorbent pad 200 further comprises a non-absorbent border region 350. A high-performance absorbent pad 200 consistent with the present disclosure may further comprise one or more perforations 400 (see, e.g., FIG. 5).

Packaged food, such as meat, typically compresses an absorbent pad positioned beneath the food, thereby reducing the fluid absorption capability of the absorbent pad. The weight of the food generally compresses the absorbent pad, thereby inhibiting the fluid absorption of the portion of the absorbent pad positioned beneath the food. For example, the compressed absorbent pad may have less ability to expand to accommodate absorption, thereby reducing fluid absorption. In some packaging arrangements, a cover (e.g., a film) is wrapped over the food and applies downward pressure on the food, which in turn compresses the absorbent pad and further inhibits the fluid absorption capability of the portion of the absorbent pad positioned beneath the food. In some packaging arrangements, the weight of the food and/or the pressure applied to the food by a cover causes the portion of the absorbent pad positioned beneath the food to be unable to absorb fluid shed from the packaged food, despite being at least partially dry.

To increase the total fluid absorption of the absorbent pad, without increasing the weight of the pad, the absorbent material of the absorbent pad 200 may be redistributed from an area configured to be disposed beneath the packaged food to an area configured to not be disposed beneath the packaged food. By not being positioned beneath the packaged food, the redistributed absorbent material is not compressed by packaged food and thus is able to absorb more fluid shed from the packaged food. For example, the absorbent material not disposed beneath the packaged food can expand (and not be squeezed by the packaged food) to accommodate fluid absorption. In some embodiments, the absorbent pad 200 includes the same amount of absorbent material as a conventional continuous or full-coverage absorbent pad, but at least some of the absorbent material is moved from areas beneath the packaged food to areas surrounding a periphery of the packaged food, thereby increasing the total fluid absorption of the absorbent pad 200 relative to conventional continuous or full-coverage absorbent pads while using the same amount of absorbent material.

Referring to FIGS. 2-6, the absorbent pad 200 may include at least one non-absorbent region 300 configured for at least partial placement beneath a packaged food, and may include at least one absorbent region 100 configured for at least partial placement around the packaged food. Generally, absorbent material is shifted from a central area of the absorbent pad 200 to an edge or peripheral area of the absorbent pad 200 to reduce (e.g., avoid) direct load from the packaged food that compresses the absorbent pad 200, thereby increasing fluid absorption by reducing the squeeze effect of absorbed fluid from the pad 200. Concentration of absorbent material along the edge or periphery of the pad 200 promotes edge wicking, thereby increasing fluid absorption.

Referring now specifically to FIGS. 6A-6B, in some embodiments, the at least one absorbent region 100 comprises an absorbent multilayer film 120, and the at least one non-absorbent region 300 comprises a non-absorbent multilayer film 320, as disclosed herein. As illustrated in FIGS. 6A-6B, the absorbent multilayer film 120 may form a portion of the absorbent pad 200 that includes the first layer 10, the second layer 20, and an absorbent material (e.g., optional third layer 30 and absorbent layer 40 in FIG. 6A, and superabsorbent layer 41 and absorbent fiber layer 42 in FIG. 6B) positioned between the first layer 10 and the second layer 20. As further illustrated in FIGS. 6A-6B, the non-absorbent multilayer film 320 may form a portion of the absorbent pad 200 that includes the first layer 10 and the second layer 20. In other words, in FIGS. 6A-6B, the absorbent multilayer film 120 differs from the non-absorbent multilayer film 320 due to the inclusion of an absorbent material in the absorbent multilayer film 120.

Referring still to FIGS. 6A-6B, the absorbent multilayer film portions 120 of the absorbent pad 200 are spaced apart from one another by the non-absorbent multilayer film portions 320 of the absorbent pad 200 to define channels or voids 324 between the absorbent multilayer film portions 120. The channels or voids 324 facilitate flow of fluid shed from the packaged food along the edges of the absorbent multilayer film portions 120 to facilitate absorption (e.g., via wicking) of the fluid into the absorbent multilayer film portions 120.

Referring now to FIG. 2, the present disclosure provides a high-performance absorbent pad 200 comprising a non-absorbent region 300 surrounded by an absorbent region 100. In some embodiments, the non-absorbent region 300 has a shape, such as a regular shape like a circle, an oval, an ellipse, a quadrilateral, a square, a rectangle, a squircle, a triangle, a pentagon, a hexagon, a heptagon, an octagon, etc.

In some embodiments, the absorbent region 100 surrounds or substantially surrounds the non-absorbent region 300. In some embodiments, the absorbent region 100 has a substantially rectangular or a substantially square cross sectional shape.

In some embodiments, the non-absorbent region 300 is sized to enable a food product, or a substantial fraction of the food product, to rest on the non-absorbent region 300 with no or substantially no fraction of the food product resting on the surrounding absorbent region 100.

In some embodiments, the high-performance absorbent pad 200 comprises a border region 350 surrounding the absorbent region 100. In some embodiments, the border region comprises a non-absorbent multilayer film 320 (see, e.g., FIG. 1E). In some embodiments, the non-absorbent multilayer film 320 comprises a third layer 30 (see, e.g., FIGS. 1A-1B) comprising, consisting essentially of, or consisting of cellulose (e.g., a cellulose tissue). In some embodiments, the third layer 30 of the multilayer film is in fluid communication with the absorbent layer 40 of the absorbent multilayer film 120 (see, e.g., FIGS. 1A-1D) of the absorbent region 100, such that fluid in contact with the third layer 30 of the non-absorbent multilayer film 320 can be absorbed by the absorbent layer 40 of the absorbent multilayer film 120.

In some embodiments, the high-performance absorbent pad 200 comprises at least one perforation line 400 (see, e.g., FIG. 5). In some embodiments, the at least one perforation line 400 is disposed between two adjacent border regions 350 (see, e.g., FIG. 2) on adjacent and connected high-performance absorbent pads 200. In such embodiments, the two or more adjacent and connected high-performance absorbent pads 200 can be separated from each other prior to use by tearing along the at least one perforations 400.

Referring now to FIG. 3, the present disclosure provides a high-performance absorbent pad 200 comprising a non-absorbent region 300 flanked on opposing sides by two absorbent regions 100. In some embodiments, the non-absorbent region 300 is not fully surrounded by absorbent regions 100.

In some embodiments, the absorbent region 100 has a substantially rectangular or a substantially square cross sectional shape. In some embodiments, each absorbent region 100 has an elongated shape, such as a rectangle, a pill shape, a trapezoid, or a parallelogram. In some embodiments, the absorbent regions 100 are substantially parallel to each other.

In some embodiments, the non-absorbent region 300 is sized (e.g., the absorbent regions 100 are spaced apart sufficiently) to enable a food product, or a substantial fraction of the food product, to rest on the non-absorbent region 300 with no or substantially no fraction of the food product resting on the flanking absorbent regions 100.

In some embodiments, the high-performance absorbent pad 200 comprises a border region 350 surrounding the absorbent regions 100 and the non-absorbent region 300. In such embodiments, the border region 350 is adjacent to the non-absorbent region 300 at two or more locations. In some embodiments, the border region comprises a non-absorbent multilayer film 320 (see, e.g., FIG. 1E). In some embodiments, the non-absorbent multilayer film 320 comprises a third layer 30 (see, e.g., FIGS. 1A-1B) comprising, consisting essentially of, or consisting of cellulose (e.g., a cellulose tissue). In some embodiments, the third layer 30 of the non-absorbent multilayer film 320 is in fluid communication with the absorbent layer 40 of the absorbent multilayer film 120 (see, e.g., FIGS. 1A-1D) of the absorbent regions 100, such that fluid in contact with the third layer 30 of the non-absorbent multilayer film 320 can be absorbed by the absorbent layer 40 of the absorbent multilayer film 120.

In some embodiments, the high-performance absorbent pad 200 comprises at least one perforation line 400 (see, e.g., FIG. 5). In some embodiments, the at least one perforation line 400 is disposed between two adjacent border regions 350 (see, e.g., FIG. 2) on adjacent and connected high-performance absorbent pads 200. In such embodiments, the two or more adjacent and connected high-performance absorbent pads 200 can be separated from each other prior to use by tearing along the at least one perforations 400.

Referring now to FIG. 4, the present disclosure provides a high-performance absorbent pad 200 comprising a plurality of non-absorbent regions 300 each flanked on opposing sides by two absorbent regions 100. In some embodiments, the non-absorbent regions 300 are not fully surrounded by absorbent regions 100.

In some embodiments, the absorbent region 100 has a substantially rectangular or a substantially square cross sectional shape. In some embodiments, each absorbent region 100 has an elongated shape, such as a rectangle, a pill shape, a trapezoid, or a parallelogram. In some embodiments, the absorbent regions 100 are substantially parallel to each other.

In some embodiments, the non-absorbent regions 300 are sized (e.g., the absorbent regions 100 are spaced apart sufficiently) to enable a food product, or a substantial fraction of the food product, to rest on the non-absorbent region 300 with a substantially smaller fraction of the food product resting on the flanking absorbent regions 100.

In some embodiments, the high-performance absorbent pad 200 comprises a border region 350 surrounding the absorbent regions 100 and the non-absorbent regions 300. In such embodiments, the border region 350 is adjacent to each of the non-absorbent regions 300 at two or more locations. In some embodiments, the border region comprises a non-absorbent multilayer film 320 (see, e.g., FIG. 1E). In some embodiments, the non-absorbent multilayer film 320 comprises a third layer 30 (see, e.g., FIGS. 1A-1B) comprising, consisting essentially of, or consisting of cellulose (e.g., a cellulose tissue). In some embodiments, the third layer 30 of the non-absorbent multilayer film 320 is in fluid communication with the absorbent layer 40 of the absorbent multilayer film 120 (see, e.g., FIGS. 1A-1D) of the absorbent regions 100, such that fluid in contact with the third layer 30 of the non-absorbent multilayer film 320 can be absorbed by the absorbent layer 40 of the absorbent multilayer film 120.

In some embodiments, the high-performance absorbent pad 200 comprises at least one perforation line 400 (see, e.g., FIG. 5). In some embodiments, the at least one perforation 400 is disposed between two adjacent border regions 350 (see, e.g., FIG. 2) on adjacent and connected high-performance absorbent pads 200. In such embodiments, the two or more adjacent and connected high-performance absorbent pads 200 can be separated from each other prior to use by tearing along the at least one perforation line 400.

Referring now to FIG. 5, the present disclosure provides a high-performance absorbent pad 200 comprising a plurality of absorbent regions 100 each surrounded by non-absorbent regions 300. In some embodiments, the non-absorbent regions 300 are continuous with each other, while the plurality of absorbent regions 100 are discrete.

In some embodiments, each absorbent region 100 has a substantially rectangular or a substantially square cross sectional shape. In some embodiments, each absorbent region 100 has a consistent shape and size. In some embodiments, each absorbent region 100 has a regular shape, such as a rectangle, a pill shape, a trapezoid, or a parallelogram. In some embodiments, the absorbent regions 100 are spaced apart from each other at substantially regular intervals.

In some embodiments, the non-absorbent regions 300 are sized (e.g., the absorbent regions 100 are spaced apart sufficiently) to enable a food product, or a substantial fraction of the food product, to rest on the non-absorbent regions 300 with a substantially smaller fraction of the food product resting on the absorbent regions 100.

In some embodiments, the high-performance absorbent pad 200 comprises a border region 350 surrounding the absorbent regions 100 and the non-absorbent regions 300. In such embodiments, the border region 350 is adjacent to the non-absorbent regions 300. In some embodiments, the border region comprises a non-absorbent multilayer film 320 (see, e.g., FIG. 1E). In some embodiments, the non-absorbent multilayer film 320 comprises a third layer 30 (see, e.g., FIGS. 1A-1B) comprising, consisting essentially of, or consisting of cellulose (e.g., a cellulose tissue). In some embodiments, the third layer 30 of the non-absorbent multilayer film 320 is in fluid communication with the absorbent layer 40 of the absorbent multilayer film 120 (see, e.g., FIGS. 1A-1D) of the absorbent regions 100, such that fluid in contact with the third layer 30 of the non-absorbent multilayer film 320 can be absorbed by the absorbent layer 40 of the absorbent multilayer film 120.

In some embodiments, the high-performance absorbent pad 200 comprises at least one perforation line 400 (see, e.g., FIG. 5). In some embodiments, the at least one perforation line 400 is disposed between two adjacent border regions 350 (see, e.g., FIG. 2) on adjacent and connected high-performance absorbent pads 200. In such embodiments, the two or more adjacent and connected high-performance absorbent pads 200 can be separated from each other prior to use by tearing along the at least one perforations 400. In some embodiments, the one or more perforations 400 include a plurality of perforations 400 that are spaced apart at irregular intervals.

Accordingly, in some embodiments, the present disclosure provides a high-performance absorbent pad 200 comprising a first absorbent multilayer film 120, wherein the first absorbent multilayer film 120 comprises a first layer 10, which may comprise a non-permeable film for contacting a food product; a second layer 20, which may comprise a permeable film, substantially opposite the first layer 10; an optional third layer 30 disposed between the first layer 10 and the second layer 20; and an absorbent layer 40 disposed between the first layer 10 and the second layer 20. In some embodiments, the fourth layer 40 is disposed between the third layer 30 and the second layer 20. In some embodiments, the fourth layer 40 is disposed between the third layer 30 and the first layer 10. In some embodiments, the first absorbent multilayer film 120 comprises an adhesive layer 50 in contact with the first layer 10 and disposed between the first layer 10 and the fourth layer 40. In some embodiments, the first layer 10 comprises, consists essentially of, or consists of polyethylene. In some embodiments, the second layer 20 comprises, consists essentially of, or consists of a non-woven film. In some embodiments, the fourth layer 40 comprises, consists essentially of, or consists of fibrous wood pulp. In some embodiments, the fourth layer 40 comprises, consists essentially of, or consists of an absorbent polymer.

In some embodiments, the high-performance absorbent pad 200 comprises a second non-absorbent multilayer film 320 comprising a first layer 10, which may comprise a non-permeable film for contacting a food product; and a second layer 20, which may comprise a permeable film, substantially opposite the first layer 10. In some embodiments, the second non-absorbent multilayer film 320 does not include an absorbent layer comprising fibrous wood pulp and/or absorbent polymers.

In some embodiments, the high-performance absorbent pad 200 comprises at least one absorbent region 100 including the first absorbent multilayer film 120, and at least one non-absorbent region 300 including the second non-absorbent multilayer film 320. In some embodiments, the high-performance absorbent pad 200 comprises a plurality of rows of the at least one absorbent region 100 separated by a plurality of rows of the at least one non-absorbent region 300. In some embodiments, the at least one absorbent region 100 forms a border around the at least one non-absorbent region 300, optionally wherein the border formed by the at least one absorbent region 100 is surrounded by a border 350 of a second non-absorbent region. In some embodiments, the high-performance absorbent pad 200 comprises a strip of the at least one non-absorbent region 300 flanked by two strips of the at least one absorbent region 100. In some embodiments, the high-performance absorbent pad 200 comprises a plurality of discrete zones of the at least one absorbent region 100, wherein each discrete zone is surrounded by the at least one non-absorbent region 300. In some embodiments, the high-performance absorbent pad 200 further comprises at least one perforation line 400 for customizing a finished size of the high-performance absorbent pad 200. In some embodiments, the at least one perforation line 400 is formed through the second non-absorbent multilayer film 320. In some embodiments, the at least one perforation line 400 is not formed through the first absorbent multilayer film 120.

In some embodiments, the present disclosure provides a superabsorbent multilayer film comprising a first layer, which may comprise a non-permeable film for contacting a food product; a second layer, which may comprise a permeable film, substantially opposite the first layer; a third layer disposed between the first layer and the second layer, wherein the third layer comprises a superabsorbent polymer; and a fourth layer disposed between the first layer and the second layer, wherein the fourth layer comprises an absorbent material. In some embodiments, the superabsorbent polymer is disposed between first and second cellulose tissue layers. In some embodiments, the absorbent material comprises, consists essentially of, or consists of cellulose fibers. In other embodiments, the absorbent material comprises, consists essentially of, or consists of at least one layer of absorbent paper. In some embodiments, a high-performance absorbent pad according to the present disclosure comprises a superabsorbent multilayer film as described herein. In some embodiments, the high-performance absorbent pad further comprises a second multilayer film, wherein the second multilayer film comprises a first layer, which may comprise a non-permeable film for contacting a food product; and a second layer, which may comprise a permeable film, substantially opposite the first layer. In some embodiments, the permeable film comprises a nonwoven material. In some embodiments, the non-permeable film comprises polyethylene.

In embodiments including a border 350, the border 350 may include a non-absorbent multilayer film 320. In such embodiments, the non-absorbent multilayer film 320 includes a cellulose layer (e.g., cellulose tissue). In such embodiments, the cellulose layer may be in fluid communication with the fourth absorbent layer 40 of the first absorbent multilayer film 120 of the absorbent regions 100, such that fluid in contact with the cellulose layer exposed at the edge of the high-performance absorbent pad 200 can be absorbed by the fourth absorbent layer 40.

3. Food Packaging Including High-Performance Absorbent Pads

Referring now to FIGS. 7-8, the present disclosure provides food packaging comprising a tray T and any high-performance absorbent pad 200 disclosed herein. In some embodiments, the high-performance absorbent pad 200 is sized to cover or substantially cover the interior surface of the tray T. In some embodiments, the absorbent region(s) 100 and the non-absorbent region(s) 300 are sized and shaped to accommodate a food product MEAT placed thereon. In one embodiment, the pad 200 with absorbent multilayer film 120 is oriented so that first layer 10 is the food contact layer, while second layer 20 is in contact with the tray T.

4. Packaged Food Products Including High-Performance Absorbent Pads

Referring again to FIGS. 7-8, the present disclosure provides a packaged food product comprising a tray T fitted with any high-performance absorbent pad 200 as disclosed herein. The packaged food product further comprises a food product MEAT in contact with the high-performance absorbent pad 200. In some embodiments, the high-performance absorbent pad 200 is oriented in the tray T such that the food product MEAT is in direct contact with the first layer 10 of the high-performance absorbent pad 200, and the second layer 20 of the high-performance absorbent pad 200 is in direct contact with the interior surface of the tray T. A cover 500, such as a heat-shrinkable plastic film, may be wrapped over the food product MEAT and in contact with the outside surface of the tray T to contain the food product MEAT within the packaging.

5. Methods of Packaging Food Using High-Performance Absorbent Pads

In some embodiments, the present disclosure provides methods of packaging food using high-performance absorbent pads 200.

In some embodiments, the present disclosure provides a method of packaging a food product, the method comprising inserting a high-performance absorbent pad 200 into a tray T; placing a food product MEAT onto at least a portion of a non-absorbent region 300 of the high-performance absorbent pad 200; and covering the food product MEAT and the tray T with a cover. In some embodiments, the step of inserting the high-performance absorbent pad 200 comprises arranging the high-performance absorbent pad 200 so that the second layer 20 of the first absorbent multilayer film 120 is in contact with an interior surface of the tray T. In some embodiments, the cover comprises a sealing film. In some embodiments, the method comprises a step of sizing the high-performance absorbent pad 200 to fit within the tray T. In some embodiments, the step of sizing comprises tearing the high-performance absorbent pad 200 along one or more perforations 400. In some embodiments, the one or more perforations 400 are not formed through the first absorbent multilayer film 120. In some embodiments, the step of sizing comprises cutting the high-performance absorbent pad 200. In some embodiments, the step of cutting does not include cutting the high-performance absorbent pad 200 through the first absorbent multilayer film 120.

6. Methods of Making High-Performance Absorbent Pads

High-performance absorbent pads 200 and the component multilayer films 120, 320 disclosed herein consist or consist essentially of food-grade materials, such as food-grade polyethylene film.

To make high-performance absorbent pads 200 of the present disclosure, such as those shown in FIG. 6A, an absorbent polymer 44 may be added to wood pulp 42 (e.g., cellulose fibers) in expanded (e.g., “fluffed”) form. In some embodiments, the wood pulp 42 (e.g., cellulose fibers) are first transformed into expanded form from a cell fiber hard sheet material. After the absorbent polymer 44 has been added to the wood pulp 42 to form the absorbent layer 40, the third layer 30 (e.g., cellulose tissue) is laid on top of the absorbent layer 40. The third layer 30 provides support for cutting the absorbent layer 40 into any desired shape and size. In some embodiments, the third layer 30 and the absorbent layer 40 are compressed before and/or after cutting.

The cut absorbent layer 40 and third layer 30 is then placed between the first layer 10 and the second layer 20. In some embodiments, an adhesive 50 (e.g., a hot adhesive such as TECHNOMELT DM 612D DISPOMELT (Henkel Corp, Rocky Hill Conn.)) is applied to the first layer 10 before the absorbent layer 40 is inserted between the first layer 10 and the second layer 20.

In some embodiments, a desired pattern of absorbent regions 100 and non-absorbent regions 300 is formed by feeding the cut absorbent layer 40 in between feeds of the first layer 10 and the second layer 20. In such embodiments, the cut absorbent layer 40 is fed at a relatively lower speed than the speed at which the first layer 10 and the second layer 20 are fed in a feed, for example in a continuous or substantially continuous production process.

In other embodiments, the desired pattern of absorbent regions 100 and non-absorbent regions 300 is formed by placing the absorbent regions 100 at desired locations on a non-moving sheet of the first layer 10 or on a non-moving sheet of the second layer 20. In such embodiments, sections of high-performance absorbent pad 200 are formed substantially in a batch-wise manner.

Referring now specifically to FIG. 6B, high-performance absorbent pads 200 according to some embodiments of the present disclosure are made by placing a superabsorbent polymer 44 between layers of cellulose tissue 35 (see, e.g., FIG. 1C) to form a superabsorbent layer 41. An absorbent wood pulp 42 (e.g., cellulose fibers) may be joined with the superabsorbent layer to form an absorbent layer 40 (see, e.g., FIG. 1C). Absorbent layer 40 may then be placed in a desired pattern between a first layer 10 and a second layer 20 to form a high-performance pad 200 comprising absorbent regions 100 and non-absorbent regions 300. The desired pattern of absorbent regions 100 and non-absorbent regions 300 may be formed in the same manners as described above, for example by feeding cut sections of the absorbent layer 40 at a relatively slower feed rate than the feed rates of the first layer 10 and the second layer 20.

Example

A high-performance absorbent pad consistent with the present disclosure and having a design consistent with FIGS. 1A, 1D, 1E, and 3 was prepared according to PLSA-425 Pad Type standards using Golden Isles® Fluff Pulp, Grade 4881 (Cat. no. 4881; GP Cellulose, LLC) as the absorbent fibers 42, 17 GSM White Surfactant SB Basecode (Cat. no. W0334CD; Berry Plastics Corp.) as the second layer 20, and DLF.7J-LFWHITE-NP-14X35000 (Cat. no. 100056813; Sealed Air Corp.) as the first layer 10. A control absorbent pad having a continuous absorbent region using the same amount (e.g., mass) of absorbent material as the high-performance absorbent pad was prepared according to PLSA-425 Pad Type standards. Both pads had dimensions of 12.5 inches by 5.7 inches.

Fluid and load were applied to each pad according to the standard Production Quality Control method. Results are shown in Table 1 below.

TABLE 1 Absorption of High-Performance Absorbent Pads vs. Control Absorbed Fluid Difference vs. Pad Description Dimensions Under Load¹ Control Control 12.5 × 5.7 in. 346.61 mL — (Continuous Absorbent Region) High-Performance 12.5 × 5.7 in. 388.38 mL +12.05% Absorbent Pad ¹Production Quality Control method.

This Example demonstrates that high-performance absorbent pads consistent with the present disclosure provide improved fluid absorption than standard absorbent pads having a continuous absorbent region.

DEFINITIONS & CONCLUSION

As used herein, and except as otherwise discernable from the context of use, the term “meat” includes, but is not limited to, beef, pork, sheep, goats, poultry (e.g., chicken, duck, goose, pheasant, turkey, quail, squabs, etc.), seafood (e.g., fish, lobster, crab, scallops, mussels, mollusks, shrimp, oysters, squid, octopus, geoduck, etc.), frogs, or any other edible animal flesh, such as any animal flesh meeting the definition of “fish,” “game animal,” “poultry,” “meat,” “molluscan shellfish,” “shellstock,” or “shucked shellfish” as set forth in 18 C.F.R. §1-201.10(B).

From the foregoing, it will be appreciated that specific embodiments of the invention have been described herein for purposes of illustration, but that various modifications may be made without deviating from the scope of the invention. Accordingly, the invention is not limited except as by the appended claims. 

1. An absorbent pad comprising: a first layer for contacting a food product; a second layer substantially opposite the first layer; and an absorbent material disposed between the first layer and the second layer, the absorbent material forming part of at least one absorbent region of the absorbent pad disposed adjacent to at least one non-absorbent region of the absorbent pad arranged for placement beneath at least a portion of the food product.
 2. The absorbent pad of claim 1, wherein the at least one absorbent region forms a border around the at least one non-absorbent region.
 3. The absorbent pad of claim 1, wherein the at least one absorbent region and the at least one non-absorbent region comprises a plurality of rows of absorbent regions separated by a plurality of rows of non-absorbent regions.
 4. The absorbent pad of claim 1, wherein the at least one absorbent region comprises two strips, and the at least one non-absorbent region comprises a strip that is flanked by the two strips of the at least one absorbent region.
 5. The absorbent pad of claim 1, wherein the at least one absorbent region comprises a plurality of discrete zones, and each discrete zone is surrounded by the at least one non-absorbent region.
 6. The absorbent pad of claim 1, wherein the at least one non-absorbent region defines at least one channel or void that facilitates flow of fluid along the absorbent pad.
 7. The absorbent pad of claim 6, wherein the at least one channel or void is formed in the second layer.
 8. The absorbent pad of claim 1, wherein the first layer comprises a non-permeable film.
 9. The absorbent pad of claim 1, wherein the first layer comprises polyethylene.
 10. The absorbent pad of claim 1, wherein the second layer comprises a permeable film.
 11. The absorbent pad of claim 1, wherein the second layer comprises a non-woven film.
 12. The absorbent pad of claim 1, wherein the absorbent material comprises fibrous wood pulp.
 13. The absorbent pad of claim 1, wherein the absorbent material comprises an absorbent polymer.
 14. The absorbent pad of claim 1, wherein the absorbent material comprises a superabsorbent polymer disposed between layers of backing material.
 15. The absorbent pad of claim 1, wherein the at least one absorbent region comprises a first multilayer film, and the at least one non-absorbent region comprises a second multilayer film.
 16. The absorbent pad of claim 1, wherein at least one perforation is formed through the non-absorbent region for customizing a finished size of the absorbent pad.
 17. The absorbent pad of claim 16, wherein the at least one perforation is not formed through the absorbent region.
 18. A packaged food product comprising: a tray; the absorbent pad of claim 1 positioned in the tray; a food product in contact with the first layer and the at least one non-absorbent region of the absorbent pad; and a cover in contact with the tray for retaining the food product within the tray.
 19. A method of packaging a food product, the method comprising: inserting the absorbent pad of claim 1 into a tray; placing a food product onto the at least one non-absorbent region of the absorbent pad; and covering the food product and the tray with a cover.
 20. The method of claim 19, wherein the step of placing a food product comprises arranging the food product so that the at least one absorbent region at least partially surrounds a periphery of the food product. 